Cast hinge

ABSTRACT

A cast hinged article made by simultaneously casting both parts of the article. A first part of the article is formed with inner projections, and a second part of the article is formed thereover to enclose the projections to provide a hinged pivot. A staking unit which includes a punch then distorts the material in the first part adjacent the projections so that the pivot will be freely movable.

United States Patent 1 Hannes I45] July 3,1973

[ CAST HINGE [75] Inventor: Karl Hannes, White Plains, NY.

[73] Assignee: Coats & Clark, Inc., New York, NY.

[22] Filed: Oct. 7, 1971 [2l] Appl. No.: 187,427

[52]- U.S.'Cl. 16/128,"!6/17! [51 E05d 9/00 [58] Field of Search l6/l7l, 12.8

[561 References Cited UNITED STATES PATENTS 1497908 3/1970 Zamarra ..l6/l7l Primary Examiner-Bernard A. Gelak Assistant Exa'minerDoris L. Troutman Attorney-Burgess, Ryan and. Wayne [57] ABSTRACT A cast hinged article made by simultaneously casting both parts of the article. A first part of the article is formed with inner projections, and a second part of the article is formed thereover to enclose the projections to provide a hinged pivot. A staking unit which includes a punch then distorts the material in the vfirst part adjacent the projections so that the pivot will be freely movable.

3 Claims, 14 Drawing Figures PAIENIEDJUL 3 I975 3. 742.555

sum 1 [IF 3 PATENTEDJUL awn 3.742.555

' sum 3 0F 3 CAST HINGE BROAD STATEMENT OF INVENTION DESCRIPTION OF THE PRIOR ART It is known in the prior art to cast pivotal or hinged elements to form an integral 'unit. An example of such casting is shown in U.S. Pat. No. 2,819,494 issued on Jan. 14, 1958 to Louis H. Morin. In such prior art casting a pivot was provided that would allow one element to be rotated with respect to the other. However, in this type 'of casting where a second element is formed over a prior formed element, a degree of binding is present so that the relative movement of the two elements is not freely rotatable. In the aforementioned patent this is not necessarily a disadvantage since a belt buckle is the product involved. However, for other elements, such as a hinge, where this type of casting process is utilized, movement of the pivot free of binding is desired.

DESCRIPTION OF THE INVENTION The present invention provides a product comprising hinged elements wherein one element is treated to be freely movable with respect to the other element.

In the present invention a hinged product is provided wherein one element is formed with projections and a second element is formed thereover to provide a pivot with the first element being distorted so that the pivot is freely movable.

A further provision of the subject invention is the provision of connected elements forming a hinge wherein a first one of the elements is formed with projections and the other element is formed thereover to formed with projections and casting a second element provide a pivot for the hinge, and depression means are tions to provide a pivotal hinge, and staking means are I provided including a punch to distort the material in the first element to free the pivot.

There is also provided casting apparatus including movable dies to form a first element with projections and a second element cast thereoverto form a pivot on the projections, and a separately located staking means has resiliently mounted parts to hold the element while a punch distorts the material of the projections to free the pivot.

There is further provided a method of casting a first clement followed by further casting of a second element thereover in an articulated manner to form a pivot followed by deforming the first element so that the pivot is freely movable.

A further provision of the subject invention is a method of casting between movable dies'a first element forming projections thereon followed by casting a sec-,

thereover to enclose the projections in pivotal arrangement, positioning the connected elements within a staking unit and forcing a punch into the first element to spread the material of the projections to make the pivot freely movable.

A still further provision of the present invention is to fonn articulated elements between movable dies wherein one element is cast over another element to form a-hinged area, and the connected elements are positioned between staking means that include opposed relatively movable parts that press against the elements so that a punch positioned in the opposing parts can be forced into the other element to spread the material and free the hinged area. 7

In a preferred embodiment of the invention an article is provided comprising articulated elements of which the first element is formed with projections around which the second element has been formed to provide a pivotal joint. The first element includes depression means formed therein which distort and spread thematerial in the area of the projections. In the embodiment illustrated a pair of spaced parallel depressions are formed in the first element to provide for the movement of the projections which releases any binding between the first and second elements. The article can be made in the form of a decorative hinge, and the inclusion of the depression means provides a freely movable pivot area.

The invention further includes casting apparatus for forming the articledescribed hereinabove. The casting apparatus includes-relatively movable dies having matable molds in which the article is formed by casting a second element around a previously cast first element so as to be pivotally movable therewith, and staking means are provided to be positioned on either side of the elements and including a punch to distort the material in one of the elements for free movement of the pivot. The staking means comprise opposed separate housings positioned on either side of the articulated element after it is moved between the housing. Each of the housings includes a relatively flat member that can be pressed against .one side of the articulated article, and the other side of the member is pressed against biasing means to provide relative movement during the punching of the article. The punch slides within the housing and the biasing means and through one of the members. The end of the punch has a pair of parallel raised areas with curved surfaces to spread the material as explained above. I

The present invention further includes a method of casting an article between relatively movable dies wherein heated material is flowed into the molds in the dies toform a first element which is then moved to the next cavity and additional heated material is flowed in to form a second element thereabout in an articulated and pivotal arrangement. The articulated element then moves to a stakingposition between opposing units that contact the articulated. elements on either side and a punch then depresses the material around the pivot area for deformation to provide free movement of the pivot. The method includes the formation of projections on the first element and enclosures on the second element around the projections so that the distortion by the spreading of the material allows the projections to be freely pivotable. In the staking position the opposed units are moved toward each other, and the punch is slid through one of the opposed units to contact a surface of the one element adjacent'the projections.

The nature of the present invention will become more clearly apparent and better understood from the following description and accompanying drawings in which:

FIG. 1 is an elevational view of one side of the hinged article of the present invention showing the decorative formation thereon;

FIG. 2 is an elevational view of the other side of the hinged product showing the flat-sided formation and depressions formed therein;

FIG. 3 is a side view of the hinged product shown in FIGS. 1 and 2;

FIG. 4 illustrates the installation of the article shown in FIGS. 1-3;

FIG. 5 is a view similar to FIG. 2 showing a lower element of the formed article in enlarged form;

FIG. 6 is a perspective view of an upper element of the formed article;

FIG. 7 is a diagrammatic view illustrating the apparatus and method for forming the article shown in FIGS. 1-3;

FIG. 8 is an exploded perspective view of one opposed means that provides the distortion of the element shown in FIG. 5;

FIG. 9 is an exploded perspective view of another opposed means that provides the distortion of the lower element shown in FIG. 5;

FIG. 10 is a view of the opposed means shown in FIGS. 8 and 9 in assembled condition prior to contacting the formed article for a distortion step;

FIG. 11 is an elevational view of punch means located in the opposed means;

FIG. 12 is an end view of the punch means shown in FIG. 1 1;

FIG. 13 is a plan view of part of the shown in FIG. 11; and

FIG. 14 is a perspective view of part of the end of the punch means showing raised areas thereon.

It will be understood that the accompanying drawings are merely diagrammatic illustrations, and reference should be made to the following description for a more detailed explanation of the structure involved.

FIGS. 1-3 illustrates the articulated article of the present invention. The article has a front decorative side 22 as shown in FIG. 1 and a rearflat side 24 as shown in FIG. 2. The article illustrated is a decorative hinge although it is to be understood that the invention is not to be so limited since the invention is considered to encompass any articulated element to be provided with a freely movable pivot. Front surface 22 of the hinge includes a decorative surface such as the illustrated embodiment of a fleur de lis pattern which includes part of the pattern formed as raised surfaces to provide the decorative effect which can be enhanced by polishing and finishing. Article 20 includes a first element or lower section 26 and a second element or upper section 28. Element 26 is connected with element 28 by a pivot or hinge means 30. As mentioned above, front surface 22 includes raised areas with cenpunch means tral area 32 in lower element 26 and central area 34 in upper element 28 being the highest raised surfaces on the article.

Hinge means 30 is provided by a pair of projections 36 formed on an inside surface of lower element 26 as shown in FIG. 5 and extending inwardly toward each other in opposed relation. Each projection 36 is tapered so that its cross-section is smallest at its remote end. Upper element 24 is formed with a pair of enclosure areas 38 as shown in FIG. 6 formed to fit respectively around the projections 36 to complete the hinge. FIG. 3 shows upper element 28 in solid lines where it is aligned with lower element26 so that the entire hinged article 20 is flat while the dotted line position of element 28 in FIG. 3 illustrates a pivoted position around hinge means 30.

-A pair of spaced holes 40 are formed in lower element 26. The particular spacing, number and location of holes 40 is not a critical feature of the invention as long as these holes are sufficiently spaced apart to receive screws, nails or other fastening means for holding the article in place when installed. Similarly, a pair of spaced holes 42 are providedin the upper element 28 for the same purpose of receiving similar fastening means for installation. Although four holes are illustrated, it is to be understood that more of less than four holes could be utilized for fastening an article such as the decorative hinge illustrated to the structure where it is utilized.

FIG. 4 illustrates a typical installation of article 20 as a hinge for a container such as a jewelry box 44. A typical decorative hinge for this purpose would be approximately 1-2 inches in length and the upper or larger element 28 would be attached to the top lid 46 of the box 44 while the lower or smaller element 26 would be attached to the back side 48 of the box 44. It is important that the pivot 30 provide a freely movable relationship between the elements so that top lid 46 does not bind and is easily rotated for opening and closing. The novel decorative hinge of the invention could also be used on louvred doors or cabinets or similar structures, and it is understood that the size and thickness of the hinge could be varied depending upon the strength required and the size of the structure involved. Similarly, the decorationcould be changed and other designs utilized as long as the freely movable pivot feature is present.

The freely movable feature of the pivot is provided by depression means 50 formed in the first element 26. As most clearly seen in FIG. 5, depression means 50 comprises a pair of spaced, parallel, elongated depressions 52 and 54 that extend longitudinally in element 26 with each depression respectively aligned generally with a projection 36. Depressions 52 and 54 are formed by a punch being forced into element 26 to thereby spread the material in the area around each projection 36. Accordingly, it will be appreciated from a consideration of FIG. 5 that depressions 52 and 54 provide a distortion of the material around each of projections 36 so that they will pivot freely within enclosures 38 of pivot hinge 30.

The casting apparatus of the invention is shown schematically in FIG. 7 where the dotted outline represents one side of a pair of movable dies within which elements 26 and 28 are formed. The general procedure of forming a first element, then moving such element to the next cavity and forming another element in articulated relation therewith is shown in the aforementioned US. Pat. No. 2,819,494. This is provided by having die 60 and a mating die relatively movable toward and away from each other to allow the vertical movement of the elements being formed in sequential steps. During the formation heated material from an injection nozzle (not shown)'flows into a gate 62 in the direction shown by arrow A. The heated material flows around a transfer core pin 64 to form a ring-like upper gate portion 66 and a lower gate portion 68. It is to be appreciated that this is a known feature to flow the heated metal into molds formed in mating dies to simultaneously form upper and lower elements in articulated form. In the upper part of the die 60 the gate 66 is seen to include paths 70 and 72 arranged to direct separate flows obliquely with respect to each other to completely form one lower element 26. Simultaneously with the flow into gate 66 there is also a flow into lower gate 68 to form the upper or second element 28 in articulated condition with a previously formed lower element that has been transposed downwardly. This is provided by flow paths 74 and 76 located obliquely with respect to each other to disperse the heated material throughout the mold in forming element 28. The articulated formationis correlated with opening and closing of the dies so that just prior to this material flowing step, the movable dies had been separated and the transfer core pin 64 had moved the previously formed element 26 down to the lower position where it is shown in FIG. 7 as element 26'. Accordingly, it is to be understood that each time the heated material flows into gate 62 and through portions 66 and 68 into the molds, a first or lower element 26 is formed in the upper position and a completed hinged article is formed in the lower position by element 28 being cast with its lower enclosure portions 38 molded around solidified projections 36. v t

It will also be seen in FIG. 7 that when first element 26 representing the lower half of the hinged article has moved downward to where it appears as a solidified element 26', then gate elements 62, 66 and 68 appear as solidified gate elements 62', 66' and 68'.

It will further be appreciated from an examination of FIG. 7 that when element 26 moves to its first lower position where it appears as solidified element 26 that an element 28 that had been previously formed then moves to a further lower or staking position where it appears as solidified element 28' where it isseen to be in articulated connection with a solidified first element 26" that had been previously formed and moved downwardly to the staking position.

The staking step is an important feature of the present invention, and the staking location is located directly below movable die 60 so that the articulated elements 26, 28 in solid form that form a completed hinged article are moved downwardly thereto by the intermittent vertical movement of the transfer core pin 64. The staking step is for the purpose of treating the first or lower element now indicated as element 26" so that its projections 36 will be freed from binding within the enclosures 38 located in element 28. It is in this staking location that element 26" is subjected to a staking or punching deformation of the material in the central area of the element to form the depression means 50. The type of material that is supplied in the heated form to be solidified is a zinc alloy which is known as Zamak No. 3. However, the invention is not to be considered to be limited to a zinc alloy, as any material of similar nature can be used which is capable of being melted and injected in the flowable form to be solidified in the mating molds.

The staking or punch operation will now be described, and it is to be noted that the staking location is just below and closely adjacent to the forming molds so that the solidified elements 26" and 28 are still in a heated condition allowing the depressions and spreading of the metal to be easily performed.

FIGS. 8 and 9 illustrate the elements that form the staking unit which are positioned in opposed relation as shown in FIG. 10. The hinged article shown as elements 26" and 28 that is to be staked or punched is moved into the lower position as shown in FIG. 10 between opposed units and 82 that are movable toward each other to respectively contact either side of the solidified hinged article. Element 80 is shown on the left side of FIG. 10 and would be movable toward the right by means not shown to be placed in contact throughout front surface 22 of hinged elements 26", 28' which includes the decorative ornamentation. For this purpose opposed unit 80 includes an outer cover or housing 84 whichincludes horizontally spaced parallel bores 86 and 88 for including therein stiff compression springs 90 and 92, respectively. The right-hand surface of housing 80 that includes the bore openings 86 and 88 is formed with a notched or depressed area 94 that is oblong in shape as shown in FIG. 7 to include the openings of bores 86 and 88 and be substantially of the same size as the hinged article 20. Within the notched area 94 is fitted one end 96 of a trim punch 100 which in cludes a raised portion 102 on its other end that is substantially of the same size and shape as the front surface of hinged element 20. From a consideration of FIG. 8 it will be seen that trim punch 100 includes the oblong shaped end portion 96 that fits within slot 94, a section 104 that extends from end 96 and has a similar but slightly smaller oblong shape with its top surface aligned with the top surface of end portion 96, the raised portion 102 which includes upper and lower parts 106 and 108 of generally the same configuration as the entire front surface 22, and a recessed groove 110 for receiving the projecting hinged area 30 of the hinged product 26", 28.

An end cover 112 fits around portion 104 to enclose trim punch 100 in place on housing 84. Cover 112 includes an oblong opening 114 that is approximately the same size as the oblong portion 104 so that it fits therearound so that part of a back surface of cover 112 is pressed against a Hat surface 103 which is the front surface of end 96 that contacts extended portion 104. Cover 1 l2 and housing 84 have a generally rectangular shape although this is not an essential feature of the invention. Cover 112 further includes a depressed area 116 in the form of three connected legs shapedto receive the solidified gates 62, 66' and 68' when they have been moved into the staking location. Accordingly, depression 116 has'generally the same shape as the gate portions shown in FlG. 7 and the trimming of the gate portions from the hinged product 26", 28' is provided at this position.

Opposed means 82 includes a housing 120 which is shaped similarly to housing 84 and includes horizontally spaced parallel bores 122 and 124 terminating in openings 126 and 128 within which stiff compression springs 130 and 132 are respectively located. on the surface of housing 120 facing hinged product 26", 28'

a recessed area 134 is formed which is oblong in shape and substantially of the same size as the hinged product 26", 28' and further includes the openings 126 and 128 as shown in FIG. 9. I

A second contacting part of trim pad 140 is provided which includes an end 142 of such oblong size that fits withing recessed area 134. Trim pad 140 is seen in FIG.

9 to include the oblong end section 142, and a raised portion 144 is formed thereon in a shape of generally the same size and corresponding to the shape of the hinged product. The surface of portion 144 is positioned to contact the back. surface of thehinged product and is generally flat to correspond with surface 24 shown in FIG. 2. It will be noticed in FIG. 9 that the top surface of raised area 144 is generally in line with the top surface of end 142, but end 142 extends further downwardly than area 144 in order to receive a cover on a flat surface 146 that is formed on a front side of end 142.

A cover 150 fits around trim pad 140 and against the inner surface of housing 120. Cover 150 includes a centrally located cut-out portion 152 which is generally of the same shape as raised portion 144 so as to fit thereabout with the rear surface of cover 150 abutting flat surface 146 as well as the inner surface 129 of housing 120. It will be seen in FIG. 9 that cover 150 includes a cut-out portion 152 that extends into the upper surface of cover 150 to form a notched opening 156 to accommodate the upper tip of hinged product 26", 28 in the position shown in FIG. 9. Cover 150 also includes a depression 154 that is in the general shape of the gate portions 62, 66' and 68'. It is to be understood that depression 154 corresponds in opposing location and shape with depression 116 to enclose the gate portions toprovide for trimming and removal thereof from the cast product.

It will be noted in FIGS. 9 and that an opening 156 is provided in the lower part of trim pad 140. A corresponding opening 158 is formed in the rear of housing 120 so that a punch 160 can be slidably positioned therein as shown in FIG. 10. It will be noted that punch 160 aswell as housing 120 and cover 150 have a generally rectangular shape, but this is not a critical feature of the invention. The function of punch 160 is to provide the staking operation wherein the punch is acted upon at one end by means not shown which would pass opening 158. The other end of punch 160 is thereby driven into the back of element 26" to form depressions 50 as described hereinbefore to spread the material and free the pivot.

As seen in FIGS. ll-l4 punch 160 is an elongated member with a generally square shape in cross section and includes chamfered edges 162 along its elongated edges. Punch 160 hasan end 164 that is forced into the lower element of product 20. End 164 includes a pair of parallel raised areas 166, and the punch and raised areas are formed of a material sufficiently hard, such as hardened tool steel, to press into the lower element 26" without deformation of the punch or raised areas. As mentioned previously, the forcing of raised areas 166 into the lower element is facilitated since the product is still in the heated condition from the molding operation.

Each raised area 166 has a particular configuration to facilitate entry and spreading of the material in order to free projections 36 from enclosures 38. As most clearly seen in FIG. 14, each raised area 166 includes an inner surface 168 projecting perpendicularly from the end 164 of punch 160. Surface 168 extends on the order of 0.02 inches and then is curved outwardly to form a curved surface 170 terminating adjacent the respective chamfered edges and outer side of the punch. The radius of the curved surface 170 is approximately 0.05 inches measured from the outer edge of surface 168. It is an important feature of the invention to have curved surfaces 170 so that the penetration by raised areas 166 is first achieved along the outer edges 172, and the continued penetrating movement of the punch causes the material to spread outwardly because of the curved surface 170. The spacing of each raised area 166 from each other is not a critical feature of the invention as long as such spacing is in general alignment with the particular location of the projections 36 so that the spreading of the alloy material is effective to move the projections into freely pivotal movement with respect to enclosures 38. The actual spread or deformation of the material is about 7-10 mils.

When the contact is made by opposed units and 82 being pressed against the opposite side of hinged product 26", 28, punch 160 is driven by the means not shown so that the raised areas 166 are forced into the back of lower element 26" to spread the material and provide the free pivotal motion. With this driving or staking step the springs 90, 92 and 130, 132 provide a resilient support for the contacting parts and so that a small amount of movement or give is permitted with respect to parts 100 and 140.

From the above description it is clear that the present invention discloses a novel articulated or hinged element wherein one element has depressions formed therein to spread the projections forming the hinge for free movement.

Another feature of the present invention is the provision of the casting apparatus for the articulated elements which includes staking or punch means that provides opposed units for contacting the articulated elements so that the punch can cause the distortion or spreading of the material for the freeing of the pivot.

A further feature of the present invention is the method of casting the article whereby the articulated elements are moved into the staking position, and the punch means are driven into one of the elements to spread the material for the loosening and free movement of the pivot.

It will be understood that various changes and modifications may be made by those skilled in the art in the particular features of the article, apparatus and method which has been described above for illustrative purposes without departing from the scope of the invention as defined by the following claims.

What is claimed is:

1. An article having first and second articulated material elements pivoted on each other wherein said first element having at least one generally flat surface is formed with a pair of inner projections facing each other in spaced-apart relation;

each said projection having a variable crosssection;

said second element having part thereof formed with a pair of enclosures to respectively enclose each of said projections and be relatively movable with respect thereto to provide the pivots;

inner edge surfaces with said outer edges having an arcuate shape so that the material of each projection is forced outwardly with respect to-its respective enclosure to provide loose pivotal movement of said projections in said enclosures.

2. An article according to claim 1 in which each said projection tapers toward its remote end.

3. An article according to claim 2 in which said enclosure comprises a pair of openings formed to corre- 10 spond respectively with said pair of tapered projections. 

1. An article having first and second articulated material elements pivoted on each other wherein said first element having at least one generally flat surface is formed with a pair of inner projections facing each other in spaced-apart relation; each said projection having a variable crosS-section; said second element having part thereof formed with a pair of enclosures to respectively enclose each of said projections and be relatively movable with respect thereto to provide the pivots; a pair of elongated slots formed in said first element, each slot spaced from a respective projection and extending in a longitudinal direction therefrom; said slots being located parallel to each other; said slots including edges and surfaces defined by the inner edge facing surfaces of each slot penetrating a predetermined distance into said first element, said inner surfaces being generally perpendicular to said first element flat surface, the outer edge of each slot being substantially absent of any penetration into said first element, and the transverse edge surfaces of each slot respectively connecting said inner edge surfaces with said outer edges having an arcuate shape so that the material of each projection is forced outwardly with respect to its respective enclosure to provide loose pivotal movement of said projections in said enclosures.
 2. An article according to claim 1 in which each said projection tapers toward its remote end.
 3. An article according to claim 2 in which said enclosure comprises a pair of openings formed to correspond respectively with said pair of tapered projections. 